Method and process for manufacturing a terminal block

Abstract

A method of manufacturing a terminal block for a telecommunication cable comprising the steps of providing a mold having a first half and a second half, each forming a respective body cavity configured to form a terminal block and configured to receive a substrate comprising a plurality of openings adapted to receive an insulated electrical contact. A plurality of projections extend from the first half into the cavity, wherein the plurality of projections are adapted to remove a portion of insulation from the electrical contact positioned within each of the openings. The substrate is positioned in the mold and the insulated electrical contact is inserted into each of the openings. The mold is closed such that the plurality of projections remove a portion of the insulation from the insulated electrical contact upon closing of the mold. A dielectric material is then injected into the mold containing the substrate and insulated electrical contact to form a terminal block. The terminal block is removed from the mold, wherein the plurality of projections form a socket adapted to receive an electrical connector.

1. A method of manufacturing a terminal block for a telecommunication cable comprising:
 providing a mold comprising:
 a first half and a second half, the first half and the second half forming a respective body cavity configured to form a terminal block and configured to receive a substrate comprising a plurality of openings adapted to receive a plurality of insulated electrical contacts; and 
 a plurality of projections extending from the first half into the cavity, wherein the plurality of projections are adapted to remove a portion of insulation from the insulated electrical contact positioned within each of the openings; 
 
 positioning the substrate in the mold; inserting the insulated electrical contact into each of the openings; 
 closing the mold, such that the plurality of projections remove a portion of the insulation from each of the insulated electrical contact upon closing of the mold; 
 injecting a dielectric material into the mold containing the substrate and each of the insulated electrical contacts to form a terminal block; and 
 removing the terminal block from the mold, wherein each projection forms a socket adapted to receive an electrical connector. 
 
   
   
     2. The method of  claim 1 , wherein each of the openings in the substrate further comprises a channel, wherein the channel extends from an outer edge of the substrate to a center portion of the opening. 
   
   
     3. The method of  claim 1 , wherein the substrate has about 2 to about 50 openings. 
   
   
     4. The method of  claim 1 , wherein the substrate can withstand a temperature greater than a temperature of the dielectric material. 
   
   
     5. The method of  claim 1 , further comprising testing an electrical connection between the plurality of projections and the insulated electrical contacts before injecting the dielectric material into the mold. 
   
   
     6. The method of  claim 1 , further comprising testing an electrical connection between the plurality of projections and the electrical insulated electrical contacts after injecting the dielectric material into the mold. 
   
   
     7. The method of  claim 1 , further comprising inserting an electrical connector into each of the sockets of the terminal block. 
   
   
     8. The method of  claim 1 , wherein the substrate is made of a dielectric material. 
   
   
     9. The method of  claim 1 , wherein the openings in the substrate have a generally oval cross-section. 
   
   
     10. The method of  claim 1 , wherein the insulated electrical contacts are insulated electrical wires. 
   
   
     11. The method of  claim 1 , wherein each insulated electrical contact is a pair of electrical wires as used in the telecommunications industry. 
   
   
     12. The method of  claim 1 , wherein each socket is configured to receive a multi-use connector. 
   
   
     13. The method of  claim 1 , further comprising gathering a cut end of the plurality of insulated electrical contacts in a bundle to form a cable. 
   
   
     14. A method of manufacturing a terminal block for a telecommunication cable comprising:
 positioning a substrate in a mold, the substrate comprising a plurality of openings adapted to receive a plurality of insulated electrical wires; 
 inserting an insulated electrical wire into each of the openings, wherein the openings receive a first end of the insulated electrical wire; 
 cutting each of the insulated electrical wires at a second end to form a bundle of wires; 
 closing the mold, such that a plurality of projections remove a portion of the insulation from each of the insulated electrical wires upon closing of the mold; 
 injecting a dielectric material into the mold containing the substrate and the insulated electrical wires to form a terminal block; 
 removing the terminal block from the mold, wherein each projection forms a socket adapted to receive an electrical connector; and inserting an electrical connector into each socket of the terminal block. 
 
   
   
     15. The method of  claim 14 , wherein the openings are configured to retain the insulated electrical wires within the openings by a groove within the opening. 
   
   
     16. The method of  claim 14 , wherein the substrate has about 2 to about 50 perforations. 
   
   
     17. The method of  claim 14 , further comprising testing an electrical connection between the projections and the insulated electrical wires before injecting the dielectric material. 
   
   
     18. The method of  claim 14 , further comprising testing and electrical connection between the projections and the insulated electrical wires after injecting the dielectric material. 
   
   
     19. The method of  claim 14 , wherein the electrical connectors are placed into the sockets after the block is removed from the mold to form an electrical connection between an exposed portion of the insulated electrical wires and the electrical connectors.